cp gp day02 session 8 waste cause analysis & cp techniques2012

Waste Cause Analysis and CP Techniques

Samantha KumarasenaDeputy DirectorNational Cleaner Production Centre, Sri Lanka

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Option generation

An organized, participative activity!

Brainstorming is a good tool!!

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Cause Analysis (Reasons for Waste)

How Do We Find Waste Causes Ask Questions

What, Why, Where, When, How Never WHO

Make Observations with CP Team Conduct Brainstorming sessions Use suitable Tools such as

Fishbone Diagram

Is the waste caused due to…

Choice & quality input

material

Choice of technology

Technical status of

equipment

Operation & maintenance

Personal skills & motivation

Product specification

Management planning & information

systems

Design & layout of plant &

machinery

Waste Cause Categories

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Choice & Quality of Input Material

• low quality• Impurities• Composition• Size of material• Cleaning requirement• Toxicity / hazardousness

IS THIS THE BEST RAW MATERIAL?

Choice of Production Technology

Obsolete technologies Available technologiesModern technologies Appropriate technology

Obsolete equipment Absence of indicator

instruments Improperly working

controllers

Technical Status of Equipment

Design and Layout of Equipment

Arrangement at the production floor

Placement and arrangement of stores

Material conveying method Long distance distribution Capacity balance Service / utility needs

Product Specification

Dimensions (size) Colors Surface finishPackaging

requirementPerformance

properties

• Inefficient process controls

• Cleanliness / housekeeping

• Correct load / parameters• Frequent down time• Power failures• Improper maintenance /

lack of maintenance planning

Operation & Maintenance

• Lack of production planning

• Wrong information• Inadequate information• Inventory management• Absence of record

keeping culture

Management Planning & Information Systems

• Attitudes• Carelessness• Short cuts• Incomplete work

Personal Skills & Motivation

Cleaner Production techniques Input substitutionGood housekeepingBetter process control Product modification Equipment modification Technology change On-site recovery/reuse Creation of useful by products

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Classification of CP Techniques

CP TECHNIQUES

PRODUCT MODIFICATION

RECYCLING

Onsite recovery and reuse

Creation ofUseful by-products

SOURCE REDUCTION

Process

Change

s

GoodHouse-Keeping

InputMaterialchange

Better process control

Equipment

modification

Technology change

Good housekeeping

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Good Housekeeping

Take appropriate operational actions to prevent:

- leaks- spills

Formulate & enforce to practice appropriate operational instructions

• Tighten valves, check & repair leaking pumps, valves, pipes to reduce/ avoid leaks

• Store chemicals in appropriate places

• Insulate steam pipes and design proper steam distribution system

Spills The spilling of dyes and chemicals at a

washing plant amounted to Rs 37,600/- per month

Drips In a rubber factory the dripping of a

chemical was estimated to be Rs 46,000/- per month

Leaks The steam leaks in a textile industry

was equivalent to 9300 liters of furnace oil (Rs 67,000/-) per month (23% of total cost)

Input substitution

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Input SubstitutionSubstitute input materials where

ever possible with- less toxic materials- renewable materials- materials with longer

lifetime

• Replace organic solvents with water• Replace Formic acid by Hydrochloric

Acid in textile dyeing• Replace chlorine bleaching with O3

bleaching• Use of soft water for preparation of dye

bath: Higher dye exhaustion levels lower dye consumption

Better process control

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Better Process ControlModify:

- operational procedures- equipment instructions

Process record keeping in order to run the processes more efficiently and at lower waste and emission generation rates

Improving process controls – e.g.

• Optimize and control operating parameters in the plant to reduce product reprocessing rate

eg: pH, temperature, time• Optimize the boiler operations

Combustion (CO2> 12%, O2< 2%)Reduce heat losses (surface, flue gas) therefore reduce fuel consumption

• Optimize fabric : liquor ratio for dyeing

Reduce energy, water and chemical consumption

Equipment modification

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Equipment ModificationModify the existing production

equipment and utilities to- run the processes at higher

efficiency- lower waste and emission

generation ratesRepair faulty equipment to reduce

losses and rejectsReplace obsolete equipment or parts

• Multiple countercurrent rinsing• Installation of hood above dryer drums

for faster moisture withdrawal • Replace solvent cleaning with

mechanical cleaning• Use of high pressure jet nozzles for

for screen washing in printing- efficient cleaning and save

water

Technology Change

Change the product & process technology in order to minimize waste and emission generation and optimize the resource efficiency

Technology change

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Product modification

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Product Modification

Modify the product characteristicsin order:

- to minimize the environmental impacts of the product during or after its use (disposal) - to minimize the environmental impacts of its production

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Product Modification

Raw Material Extraction Manufacture Transportation Use End-of-life

On-site recovery/reuse

Water, Packaging, containers !!!!

On site Recovery/Reuse

Reuse/recovery or recycling of the wasted materials in the same process or outside, for same or another application

Recovery, reuse, recycle• Water of last rinse for the first

rinse• Chrome recovery in leather

industry• In plastic injection moulding the

waste is recycled• Condensate recovery in boilers

Production of Useful By-products

Reuse of the wasted materials for manufacturing of another product.

eg:• Waste tyres are used for energy recovery• Use of fabric cuttings for mattress

manufacturing• Coconut water from DC mills

- Juice Preparation- Vinegar production

Creation of useful by products

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Your Questions

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?

Thank you!

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